Cushioned stabilizing sock and method

ABSTRACT

A cushioned stabilizing sock is described, having an inner fabric component, a midfoot stiffening component, a cushion heel component, and an outer fabric component. The sock may also have an attached or removable outer resin component. A method of making the sock comprises laying up the components upon a mold base covered by a release sheet.

BACKGROUND

The present disclosure relates in part to footwear apparatus and methods.

Various footwear types are in use to protect and cushion a user's feet. For example, some shoes may have an innersole made of a resilient material. However, the innersole may be hard to replace. Also, socks are known, made of fabric which may be placed over the user's foot and used in conjunction with shoes to be worn inside the shoes. However, conventional socks provide limited cushioning and stabilizing to the user's feet.

Hence, there is a need for an improved footwear type that avoids the disadvantages of conventional shoes and socks.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements.

FIG. 1 is a cross-sectional view of a first implementation of a cushioned stabilizing sock, supported on a mold base.

FIG. 2 is a perspective view of a mold base used in a method of making the cushioned stabilizing sock.

FIG. 3 is a perspective view of the mold base covered with a release sheet.

FIG. 4 is a perspective view of an inner fabric component placed over the release sheet.

FIG. 5 is a perspective view of a stiffening component placed over the inner fabric component.

FIG. 6 is a perspective view of a cushion heel component placed on a portion of the stiffening component and/or inner fabric component.

FIG. 7 is a perspective view of an outer fabric component placed over the components of FIG. 6.

FIG. 8 is a perspective view of a resin outside material applied to a portion of the components of FIG. 7.

FIG. 9 is a perspective view of liquid resin outside material applied to a larger portion of the components of FIG. 7.

FIG. 10 is a perspective view of a cushioned stabilizing sock removed from the mold base and release sheet.

FIG. 11 is a bottom view of the cushioned stabilizing sock of FIG. 10, showing a portion of the bottom of the cushioned stabilizing sock.

FIG. 12 is a side view of the cushioned stabilizing sock of FIGS. 1 and 10, on a user's foot.

FIG. 13 is a flow diagram of processes that may be used in making a cushioned stabilizing sock.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

In some implementations, the instant application describes cushioned stabilizing sock that includes an inner fabric component, a stabilizing component, a heel cushion component, an outer fabric component, and a resin outside material. In some implementations, a method of making a cushioned stabilizing sock using a mold base is also described.

The cushioned stabilizing sock according to variations and implementations herein may be worn alone, or may be worn inside of shoes.

Examples of some various components of items used in making the cushioned stabilizing sock, and a resulting cushioned stabilizing sock will now be described with reference to FIG. 1, which is a cross-sectional view of a first implementation of a cushioned stabilizing sock 10, supported on a mold base 12. Discussion herein and below related to other figures adds details of some implementations and alternatives of some components and methods.

The mold base 12 is a generally hard structure which may be supported on a pole 14. The mold base 12 is preferable rigid and has an outer surface shaped in the approximate size and shape of a foot, such as a human foot. A release layer 16 is shown overlying at least a portion of the mold base 12. An inner fabric component 18 is disposed over the release layer 16. Overlying a portion of the inner fabric component 18 is a stiffening component 20. A resilient heel component 22 overlies one or both of: a portion of the inner fabric component, and/or a portion of the stiffening component 20. An outer fabric component 24 surrounds the inner fabric component 18, the stiffening component 20, and the resilient heel component 22. As described elsewhere herein, the inner fabric component 18 and outer fabric component 24 together form a surround for enclosing the stiffening component 20 and the resilient heel component 22. In FIG. 1, the cushioned stabilizing sock 10 is shown still mounted on the mold base 12 and release layer 16. As described further herein, the completed cushioned stabilizing sock 10 can be removed from the mold base 12 and release layer 16, thus making a completed cushioned stabilizing sock that is ready for use. The completed sock 10 has a toe area 11, a heel area 13, a midfoot area 15, and an ankle opening 17. Various additional details of some implementations of the socks and methods are described in more detail below.

FIG. 2 is a perspective view of a mold base 12 used in a method of making the cushioned stabilizing sock. The mold base 12 may be hollow or solid, but may provide a relatively smooth outer surface. The mold base 12 may be suitably durable as to be used in the processes described herein repeatedly. The mold base 12 may be, for example, made of hard plastic and/or metal, and may be, by way of example only, an injection molded part, a hand machined part, and/or a 3-D printed part.

FIG. 3 is a perspective view of the mold base 12 covered with the release layer 16. The release layer may be a flexible plastic sheet and/or a flexible metal foil. A purpose of the release sheet 16 may be to prevent sticking or adherence of the inner fabric component 18 to the mold base 12 during the process described herein. The outer surface of the mold base 12 may alternatively have a non-stick surface so that a release layer 16 is not used.

FIG. 4 is a perspective view of an inner fabric component 18 placed over the release sheet. The inner fabric component will in use, contact the user's foot, and may be a woven or knitted fabric material having desirable properties such as smoothness, softness, elasticity, durability and/or washability. The inner fabric component 18 may be in the general shape of a sock; that is having a main body portion covering a user's foot, and an opening to accept the user's ankle so that a user's foot may be inserted into the inner fabric component 18 and into the completed cushioned stabilizing sock 10. The inner fabric component 18 may be an elastic or stretch material to conform at least in places to the shape of the user's foot. The inner fabric component 18 may have cushioning properties, insulating properties and/or moisture wicking properties.

FIG. 5 is a perspective view of a stiffening component 20 placed over the inner fabric component 18. The stiffening component 20 may cover a suitable portion of the inner fabric component 18. For example, the stiffening component 20 may cover the lower midfoot region of the fabric component 18, and/or may also cover some or all of the heel region and/or ball of foot region. The stiffening component 20 may wrap to some extent up the side of the midfoot region, heel region and/or ball of foot region. In some implementations, the stiffening component 20 may also cover the toe region. The stiffening component may be made of any of a wide range of materials. For example, it may be , an injection molded plastic piece, a rubber piece, a thick fabric piece, a 3-D printed piece, etc. The term stiffening is used to suggest that the stiffening component 20 may be relatively more stiff than the inner fabric component 18. The stiffening component 20 may, however, be of any range of flexibilities, ranging in some examples from very stiff, even completely rigid, to very flexible. The stiffening component 20 may also be a laminated material. The stiffening component 20 may also have insulating properties and/or moisture wicking properties. In some implementations, the stiffening component 20 may be comprised of two or more pieces, which may be hinged at their adjacent locations, or may have spacing between each other.

FIG. 6 is a perspective view of a heel component 22 placed on a portion of the stiffening component 20 and/or inner fabric component 18. The heel component 22 may be of a soft, resilient material that may absorb shocks to the user's foot. For example the heel component 22 may be of a foam material, such as for example EVA, and/or a material such as silicone. The heel component 22 may itself have layers or portions made of more than one respective material. The heel component 22 may also have insulating properties and/or moisture wicking properties. In some implementations, the heel component 22 may be comprised of two or more pieces, which may be hinged at their adjacent locations, or may have spacing between each other. In some implementations, the heel component 22 may overlie a portion or all of the length of the stiffening component 20, and/or overlie parts of the heel region of the of the inner fabric component 18, including the side of the foot, the ball of feet and/or toe areas. The material for the heel component 22 may be selected to be a material having desirable properties such as smoothness, softness, elasticity, durability and/or washability.

FIG. 7 is a perspective view of an outer fabric component 24 placed over the components of FIG. 6. The outer fabric component 24 will in use, have portions that form part of the outside of the cushioned stabilizing sock 10, and may be a woven or knitted fabric material having desirable properties such as smoothness, softness, elasticity, durability and/or washability. The outer fabric component 24 may be in the general shape of a sock; that is, having a main body portion covering a user's foot, and an opening to accept the user's ankle so that a user's foot may be inserted into the inner fabric component 18 and into the completed cushioned stabilizing sock 10. The outer fabric component 24 may be an elastic or stretch material to conform at least in places to the shape of the user's foot. The outer fabric component 24 may have cushioning properties, insulating properties and/or moisture wicking properties. At various places, such as for example the end of the toe area, and/or the top of the ankle area, the outer fabric component 24 may have a sewn connection to the inner fabric component 18 to enhance the overall integrity of the cushioned stabilizing sock 10. Thus, the outer fabric component 24 and the inner fabric component 18 form a chamber that encloses the stiffening component and the heel component.

FIG. 8 is a perspective view of a resin outside material component 26 applied to a portion of the components of FIG. 7. In this example, the resin outside material component 26 is applied over a second release layer 26 a, which overlies the components of FIG. 7. In the example using the second release layer 26 a, the resin outside material component will conform to the shape of the outside of the components of FIG. 7, but will result in a separate piece not attached to the components of FIG. 7. The second release layer 26 a may be any of the release layer types described above with respect to release sheet 14. In another implementation, the release layer 26 a may be omitted, and the resin outside material component 16 is adhered to an outside region of the components of FIG. 7, either by its own properties or by bonding adhesives.

FIG. 9 is a perspective view of resin outside material 26 applied to a larger portion of the components of FIG. 7, either with or without use of a second release layer 26 a. In some implementations, the resin outside material component 26 may be made of a dry-hardening or heating-and-cooling-hardening type rubber, plastic, and/or any resin material, which may be hard or soft, and may be rigid or resilient. The resin outside material component 26 may also be a laminated structure. The resin outside material component 26 may also have insulating properties and/or cushioning properties. In some implementations, the resin outside material component 26 may be comprised of two or more pieces, which may be hinged at their adjacent locations, or may have spacing between each other. The resin outside material component 26 may cover a large region of the lower part of the cushioned stabilizing sock 10 as shown, and as described above may be attached to, or separable from, the other elements of the cushioned stabilizing sock 10. In some implementations, the resin outside material component 26 may overlie a portion or all of the length of the midfoot, and/or overlie parts of the heel region, including the side of the foot, the ball of feet and/or toe areas. The material for the resin outside material component may be selected to be a material having desirable properties such as smoothness, softness, elasticity, durability and/or washability.

FIG. 10 is a perspective view of a cushioned stabilizing sock 10 removed from the mold base 10 and release sheet 14. FIG. 11 is a bottom view of the cushioned stabilizing sock 10, showing a portion of the bottom of the cushioned stabilizing sock 10. FIG. 12 is a side view of the cushioned stabilizing sock 10, on a user's foot, with the user's ankle 30 shown. In these views, visible parts are numbered with reference numbers as described above.

FIG. 13 is a flow diagram of processes 100 that may be used in making a cushioned stabilizing sock, such, for example, the cushioned stabilizing sock 10, and its variations, as described above. In process 110, a mold base is provided. In process 112, the mold base is covered with a release sheet. In process 114, an inner fabric component is placed over the release sheet. In process 116, a stiffening component is places over the inner fabric component. In process 118, a heel component is placed on a portion of the stiffening component and/or the inner fabric component. In process 120, an outer fabric component is applied over the assembly including the inner fabric component, the stiffening component and the resilient heel component. In process 122, a second release sheet is optionally applied over the outer fabric component. In process 124, a resin outside material is placed over the outer fabric component. In process 126, a resin outside material is placed over the second release sheet. In process 128, at least the assembly comprising the inner fabric component, the stiffening component, the heel component and the outer fabric component is removed from the mold base and release sheet. At process 130, the inner fabric component and outer fabric component may be sewed together, for example at the toe and ankle areas, to form an enclosure that encloses the stiffening component and the resilient heel component.

It will be appreciated that various cushioned stabilizing socks and cushioned stabilizing sock assemblies can be made according to the descriptions of the exemplary structures and methods described above. For example a one-piece sock having the resin outside material component attached to other components may be provided, or a two-piece sock having the resin outside material component as a removable component from the other components. Also at any stage, an adhesive may be applied to any components, to hold various components together.

It will also be appreciated that various cushioned stabilizing socks and cushioned stabilizing sock assemblies according to various implementations described herein can provide to a user's foot a combination of heel cushioning provided by the heel component, and/or stability provided by the stiffening component. The outer resin component can further provide an additional combination of cushioning and stability to the user's foot.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings.

Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain.

The scope of protection is limited solely by the claims that now follow. That scope is intended and may be interpreted to be as broad as is consistent with the ordinary meaning of the language that is used in the claims when interpreted in light of this specification and the prosecution history that follows and to encompass all structural and functional equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirement of Sections 101, 102, or 103 of the Patent Act, should may they be interpreted in such a way. Any unintended embracement of such subject matter is hereby disclaimed.

Except as stated immediately above, nothing that has been stated or illustrated is intended or should be interpreted to cause a dedication of any component, process, feature, object, benefit, advantage, or equivalent to the public, regardless of whether it is or is not recited in the claims.

It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter. 

What is claimed is:
 1. A footwear apparatus, comprising: an inner fabric component; a stiffening component adjacent to and outside a portion of the inner fabric component; a resilient heel component outside a portion of the fabric component; an outer fabric component surrounding the inner fabric component, the stiffening component and the heel component; and a resin component outside at least a portion of the outer fabric component.
 2. The footwear apparatus of claim 1, wherein the inner fabric component is shaped to cover a foot.
 3. The footwear apparatus of claim 2, wherein the stiffening component is a midfoot stiffing component and is made of carbon fiber and is located at least at a midfoot region of the apparatus.
 4. The footwear apparatus of claim 2, wherein the heel component is made of resilient material and is located at least at a heel portion of the apparatus.
 5. The footwear apparatus of claim 4, wherein the heel component partially directly overlies the stiffening component.
 6. The footwear apparatus of claim 4, wherein the heel component partially directly overlies the inner fabric component.
 7. The footwear apparatus of claim 4, wherein the heel component partially directly overlies the stiffening component and partially directly overlies the inner fabric component.
 8. The footwear apparatus of claim 5, wherein the outer fabric component completely surrounds an outside of the assembly comprising the inner fabric component, the stiffening component, and the resilient heel component.
 9. The footwear apparatus of claim 6, wherein the resin component partially surrounds an outside of the outer fabric component.
 10. The footwear apparatus of claim 7, wherein the resin component is bonded to the outer fabric component.
 11. The footwear apparatus of claim 7, wherein the resin component is separable from the outer fabric component.
 12. The footwear apparatus of claim 10, wherein the outer fabric component and the inner fabric component are sewn together at both a toe portion and an ankle portion respectively thereof.
 13. The footwear apparatus of claim 12, wherein the outer fabric component and the inner fabric component form a chamber enclosing the stiffening component and the resilient heel component.
 14. The footwear apparatus of claim 13, wherein the stiffening component is made of a more stiff material than the material of the resilient heel component.
 15. A method of manufacturing a footwear apparatus, comprising: providing a mold base; covering at least partially the mold base with a release sheet; covering at least partially the release sheet with an inner fabric component; covering partially the inner fabric component with a stiffening component; covering partially at least one of the inner fabric component and/or the stiffening component with a resilient heel component; covering the stiffening component and resilient heel component with an outer fabric component; sewing the inner fabric component and the outer fabric component together at a respective toe portions and ankle portions thereof to form an enclosure enclosing the stiffening component and the resilient heel component; and removing the assembly comprising the inner fabric component, the stiffening component, the heel component and the outer fabric component from the assembly comprising the mold base and release sheet.
 16. The method according to claim 15, further comprising: covering partially the outer fabric component with a resin component.
 17. The method of claim 16, wherein the process of covering partially the outer fabric component with a resin component further comprises bonding the resin component to the outer fabric component.
 18. The method of claim 16, wherein the process of covering partially the outer fabric component with a resin component further comprises placing a second release sheet over the outer fabric component.
 19. The method of claim 18, wherein the resin component is removable from the outer fabric component.
 20. The method of claim 19, wherein the resin component covers at least a heel and midfoot portion of the footwear apparatus. 